ZOMEWORKS UTR-020 TRACK RACK™ ASSEMBLY INSTRUCTIONS TOTAL SQUARE FOOTAGE OF PANELS NOT TO EXCEED 20 SQUARE FEET – DOING SO WILL VOID WARRANTY 1011 Sawmill Road NW, PO Box 25805, Albuquerque, NM 87125 USA (505) 242-5354 / (800) 279-6342 / FAX (505) 243-5187 E-mail: zomework@zomeworks.
TABLE OF CONTENTS Cover Page Page 1 Table of Contents Page 2 About Trackers Page 3 UTR-Series Parts list and Recommended Tools Page 4 - 5 UTR-Series Pole Installation Page 5 - 6 Step 1: Laying out canister set Page 7 Step 2: Bottom Rail Attachment Page 7 - 8 Step 3: Attaching the Axle Assembly Page 9 Step 4: Top Rail Attachment Page 10 - 11 Step 5: Mounting the tracker on the pole Page 11 Step 6: Shock and Bumper-Bolt Installation Page 12 Step 7: Shadow Plate Installation Page 13 Ste
ABOUT TRACKERS The UTR-Series Tracker is an ingenious and economical way to increase photovoltaic efficiency an average of 25%. Photovoltaic panels mounted on a tracker will be much more efficient than the same panels mounted on a fixed rack when the tracker follows the sun for at least 6 hours a day. Because a tracker relies on a differential of solar heat gain in the canisters, it will react quicker on a bright sunny day than it will on a partially cloudy day.
UTR-Series Parts List and Recommended Tools 4 3 2 9 10 6 7 5 8 1 12 CUSTOMER PROVIDED POLE Shadow Plates (#1) 44" long Aluminum Shadow Plates (38" spacing) 1/4"-20 x 3/8" ZP Round Head Slot Machine Screw 1/4" ZP Fender Washer 1/4" SS Lock Washer Bearings (#2) 3/4" insert bearings (pre-attached) Canister (#3) 44" x 2" Canister Top Rail (#4) Top Rail assembly w/U-Brackets 5/16" x 3" ZP Hex Bolts 5/16" ZP Flat Washers 5/16" ZP Nylock Nuts Bumper Bolt (#5) - (all parts are pre-attached) 5/8" x 4" ZP Hex Bol
/8" ZP Hex Nut Loctite Tube Module Mounting Hardware ( x # of modules ) 2" Stainless Steel J-Clip 1/4"-20 x 5/8" SS Hex Bolt 1/4"-20 x SS Hex Flange Lock Nut 1/4" SS Flat Washer 1 ea. 1 ea. Quantity 4 ea. 4 ea. 4 ea. 4 ea. Counterweight Bar & Counterweights ( #11 & 12 ) 5/8" ZP All Thread Bolt ( 17 1/4" long ) Rubber Hose ( 5 1/2" long ) 5/8" ZP Hex Nut 5/8" ZP Flat Washer 5/8" ZP Lock Washer 5/8" ZP Jamb Nut 2 1/2lb Disk Weight Quantity 1 ea. 1 ea. 2 ea. 2 ea. 2 ea. 1 ea. 8 ea.
• • The pole may be filled with concrete for added strength (only to approximate ground level). Allow concrete and pole to set for a minimum of 36 hours BEFORE installing the Track Rack™. MOUNTING POLE RECOMMENDATIONS: Description Universal UTR-020 F-Series K-Series UTRK-040 UTRF64 F-Series UTRF90 F-Series UTRF120 F-Series UTRF168 Minimum Schedule 40 Steel Pipe Min. Pole Height Min. Pole Depth 2.
Step 1: Laying out the canister set: NORTH SOUTH Diagram 1 • Remove Canister set from box and carefully unwind the copper transfer tube and place on the ground or work surface as shown. Make sure canister tabs are on the bottom.
• Separate the top rail and bottom rail and slide the bottom rail in between the canister tabs and the crossover tube. NORTH SOUTH Diagram 2b • Remove the 3/8” Bolts, Washers and Nylock Nuts from the Hardware bag and insert them through the bottom rail and canister tabs as shown and tighten completely. • Secure the 4-UV Cable Ties around both the bottom rail and the transfer tube, making sure not to pinch the transfer tube between the cable tie and the bottom rail.
Step 3: Attaching the Axle Assembly: NORTH SOUTH Diagram 3 • Remove the Axle Assembly from the box. The axle assembly will have the shock and bumper bolt taped to the bent rod. There is no need to remove them as it will make this step more difficult. The shock is also already pre-attached to the bent rod and secured with a cotter-pin. • Remove the shaft-collar and slide over the end of the axle and as far up as possible and lightly secure with the provided 5/32” Allen Wrench.
Step 4: Top Rail Attachment: NORTH SOUTH Diagram 4a • • Remove the remaining rail from the box and position as shown in Diagram 4a & 4b. Slide the rail U-brackets over the canisters and slide the entire rail up against the axle assembly, making sure to seat the axle into the bearing on the top rail.
• Remove the 5/16” bolts, flat washers and Nylock nuts from the hardware bag and insert them through the top rail U-brackets as shown in Diagram 4b and tighten enough to keep the rails from sliding on the canisters. Step 5: Mounting the Tracker on the pole: NORTH SOUTH Diagram 5 • On the gimbal can that is mounted to the axle assembly, make sure to loosen the set bolt to allow enough space for the mounting pole to slide inside.
Step 6: Shock and Bumper Bolt installation: NORTH SOUTH Diagram 6 • • • • Remove the tape and shrink wrap from the shock absorber and bumper bolt. Align the upper mount of the shock absorber with the square nut that is welded onto the top rail. Apply Loctite to the shock bolt then thread bolt into nut as far as it will go and tighten the jamb nut against the welded nut. Thread the bumper bolt into the square nut that is welded to the north side of the axle assembly on the bent rod.
Step 7: Shadow Plate Installation: SHADOW PLATES (4) 1/4"-20 x 3/8" ZP ROUND HEAD SLOT SCREWS (4) 1/4" SS LOCK WASHERS (4) 1/4" ZP FENDER WASHERS NORTH SOUTH Diagram 7 • Remove the shadow plate hardware bag from within the main hardware bag. There will be one extra set of hardware. • Screw the ¼” round head slot screws through the lock washer and then the fender washer, through the shadow plate and into the welded rectangular nuts on the canisters.
Step 8: J-clip attachment: NORTH 2" SS J-CLIPS SOUTH Diagram 8 • Remove the J-clips from the hardware bag and slide onto the top and bottom rails from the bottom as shown in Diagram 8. The J-clips on the bottom rail should be mounted with the tab facing the top rail.
Step 9: Panel installation: Diagram 9 • • • • • • Remove the ¼” Stainless steel module mounting hardware bag from the main hardware bag and fasten one side of the center solar panel, or if there are two panels then choose which to fasten first, to the top rail as shown in Diagram 9. When choosing the solar panel mounting holes, choose the holes that are 32” or less, center to center. There should also be at least 2” between the edge of the solar panels and the canisters to prevent inadvertent shading.
Step 10: Counterweight Installation: Diagram 10a • • • • Remove the Counterweight bar and the box containing the 8 – 2 1/2lb weights from the shipping box. Remove the nuts and washers from the side of the counter weight bar opposite of the jamb nut and slide all of the 2 1/2lb weights onto the bar and over the rubber sleeve. Re-thread the nuts and washers that were removed in the previous step, back onto the counterweight bar.
Step 11: Balancing the Tracker: • • • • • • The Tracker MUST be balanced above its pivot axis. Adjust the tracker to the seasonal adjustment required for your area and season. Carefully watch the tracker during its normal operation. At the end of its rotation the tracker should just come to rest on the bumper bolt. With the counterweights at their lowest location on the counterweight bar, the tracker may not rotate in its full arc throughout the day.
UTR-SERIES TRACKER TROUBLESHOOTING TRACKER SITS LEVEL, LEANS TO ONE SIDE, OR DOES NOT MOVE: 1. Manually move tracker through its entire range of motion. Check for any mechanical interference and correct if necessary. You MUST grease the bearings regularly, AT LEAST TWICE A YEAR (See warranty). 2. Check shadow plates for proper installation. The tracker will NOT work WITHOUT them. 3.
IMPORTANT NOTES TO REMEMBER: 1. The Track Rack™ must be assembled according to the instructions. 2. The Track Rack™ should move smoothly through the entire range of motion, with the only drag supplied by the shock absorbers. If friction or interference is noted, check assembly against the instructions and make required corrections. 3. The photovoltaic modules should be centered and mounted evenly as per the instructions.
ZOMEWORKS TRACK RACKTM Limited Warranty Zomeworks Corporation guarantees, to the original owner, its Track Rack™ passive solar tracker and fixed racks against defects in materials and workmanship for TEN YEARS from date of purchase. Shock absorbers and Bearings are warranted against defects in materials and workmanship for TWO YEARS from date of purchase. An extended warranty for shock absorbers and bearings is available; please contact Zomeworks Corporation for details.
